2006 FORD S-MAX Service Repair Manual

change wheel instrument cluster keyless entry drain bolt power steering dimensions

Page 2865 of 4402

$FORD S-MAX 2006 Service Repair Manual Supplement\bry\fhe\bter\f Instrument\fcluster\f B\bttery\f Ch\brging\fis\fcontrolled\fby\fthe\fPCM\f\bnd\fthe\fGEM.\fThe\fPCM\fcommunic\btes\fwith\fthe\fgener\btor\f co ntrol\fmodule\fusing\f\b\fLIN\$

Supplement\bry\fhe\bter\f
Instrument\fcluster\f
B\bttery\f
Ch\brging\fis\fcontrolled\fby\fthe\fPCM\f\bnd\fthe\fGEM.\fThe\fPCM\fcommunic\btes\fwith\fthe\fgener\btor\f
co
ntrol\fmodule\fusing\f\b\fLIN\fconnection.\fThe\fPCM\fwill\finstruct\fthe\fgener\btor\fto\fincre\bse\for\f
decre\bse\fch\brging\fvolt\bges\fin\f\bccord\bnce\fwith\fthe\frequirements\fof\fthe\fpower\fsupply\f
systems.\fIn\fturn\fthe\fgener\btor\fcontrol\fmodule\fwill\finform\fthe\fPCM\fof\fthe\fcurrent\foutput\fof\f
the\fgener\btor.\f
The\fgener\btor\fcontrol\fmodule\fmonitors\fthe\fgener\btor\foutput.\fIf\f\b\ff\bult\fdevelops\fin\fthe\f
gener\btor\fcontrol\fmodule,\fcontrol\fcircuits\for\fthe\fgener\btor,\fthe\fPCM\fwill\fbe\finformed\f\bnd\f\b\f
di\bgnostic\ftrouble\fcode\f(DTC)\fwill\fbe\fset.\f
Using\fthe\finform\btion\freceived\fby\fthe\fPCM\ffrom\fthe\fgener\btor\fcontrol\fmodule,\fthe\fPCM\fc\bn\f
c\blcul\bte\fthe\fgener\btor\flo\bd.\fThe\fgener\btor\flo\bd\finform\btion\fis\ftr\bnsferred\fto\fthe\fGEM\fusing\f
CAN\fcommunic\btion.\fThe\fGEM\fuses\fthe\flo\bd\finform\btion\fto\fc\blcul\bte\fm\bximum\f\bllow\bble\f
current\fconsumption\fof\fthe\fclim\bte\frel\bted\fsystems.\fThe\fGEM\f\blso\fcontrols\fthe\finiti\btion\fof\f
f\bult\fw\brnings\fto\fthe\fdispl\by\finform\btion\fmodule.\fThe\fb\bttery\fch\brge\fw\brning\findic\btor\fis\f
turned\foff\fby\fme\bns\fof\f\bn\finstruction\ffrom\fthe\fGEM\fusing\fCAN\fcommunic\btion.\f\f
To\freduce\fthe\flo\bd\fon\fthe\fgener\btor\fto\fwithin\fits\fworking\flimits\f\bnd\f\bssist\fwith\fb\bttery\f
recovery\f\bfter\fst\brt\fup,\fthe\fGEM\fwill\fswitch\fnon\fcritic\bl\fsystems\foff\f\bnd\fon.\f\f
The\fsystems\fth\bt\f\bre\fcontrolled\fby\fthe\fGEM\fh\bve\ftypic\bl\flo\bds\fof:\f
He\bted\fwindshield\f
70

\f\bmps\f
He\bted\fre\br\fscreen\f
25
\f\bmps\f
He\bted\fmirrors\f
4\f
\bmps\f
Supplement\bry\fhe\bting\f
80
\f\bmps\f
The\fclim\bte\fsystems\fh\bve\fbeen\fchosen\fbec\buse\fthey\fc\bn\fbe\fswitched\foff\ffor\fshort\fperiods\f
o f

\ftime\fwith\fb\brely\fdetect\bble\fch\bnges\fin\ftheir\fultim\bte\ffunction.\fDuring\fthis\fcontrol\fperiod,\f
the\ffunction\findic\btors\ffor\fthe\fsystem\fbeing\fcontrolled\fwill\frem\bin\fillumin\bted.\fThe\ftot\bl\flo\bd\f
reduction\fif\f\bll\fcontrolled\fcomponents\fwhere\fswitched\foff\fwould\fbe\fin\fthe\fregion\fof\f180\f
\bmps.\f
Conversely,\fthe\fGEM\fc\bn\fswitch\fthe\fs\bme\fcomponents\fon\f\bt\f\bny\ftime\fthereby\fincre\bsing\f
engine\flo\bd.\fThis\ffunction\fis\fused\fto\f\bssist\fwith\fthe\fengine\fw\brm\fup\fprocess.\f
Inspec\fion\band\bVerifica\fion\b
WARNINGS:\f
B\bt
teries\fcont\bin\fsulphuric\f\bcid.\fAvoid\fcont\bct\fwith\fskin,\feyes,\for\fclothing.\fAlso,\f
shield\fyour\feyes\fwhen\fworking\fne\br\fb\btteries\fto\fprotect\f\bg\binst\fpossible\fspl\bshing\fof\fthe\f
\bcid\fsolution.\fIn\fc\bse\fof\f\bcid\fcont\bct\fwith\fskin\for\feyes,\fflush\fimmedi\btely\fwith\fw\bter\ffor\f\b\f
minimum\fof\f15\fminutes\f\bnd\fget\fprompt\fmedic\bl\f\bttention.\fIf\f\bcid\fis\fsw\bllowed,\fc\bll\f\b\f
physici\bn\fimmedi\btely.\fF\bilure\fto\ffollow\fthese\finstructions\fm\by\fresult\fin\fperson\bl\finjury.\f
B\btteries\fnorm\blly\fproduce\fexplosive\fg\bses\fwhich\fc\bn\fc\buse\fperson\bl\finjury.\f
Therefore,\fdo\fnot\f\bllow\ffl\bmes,\fsp\brks\for\flighted\fsubst\bnces\fto\fcome\fne\br\fthe\fb\bttery.\f
When\fch\brging\for\fworking\fne\br\f\b\fb\bttery,\f\blw\bys\fshield\fyour\ff\bce\f\bnd\fprotect\fyour\feyes.\f
Alw\bys\fprovide\fventil\btion.\fF\bilure\fto\ffollow\fthese\finstructions\fm\by\fresult\fin\fperson\bl\f
injury.\f
1. 1.\b
Verify\fthe\fcustomer\fconcern.\f
1

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Page 2866 of 4402

$FORD S-MAX 2006 Service Repair Manual 2.2.\b Visu\blly\finspect\ffor\fobvious\fsigns\fof\fmech\bnic\bl\for\felectric\bl\fd\bm\bge.\f V isual\bInspec\fion\bChar\f\b 3. 3.\b If\f\bn\fobvious\fc\buse\ffor\f\bn\fobserved\for\freported\fconcer$

2.2.\b
Visu\blly\finspect\ffor\fobvious\fsigns\fof\fmech\bnic\bl\for\felectric\bl\fd\bm\bge.\f
V
isual\bInspec\fion\bChar\f\b
3. 3.\b
If\f\bn\fobvious\fc\buse\ffor\f\bn\fobserved\for\freported\fconcern\fis\ffound,\fcorrect\fthe\fc\buse\f
(if\fpossible)\fbefore\fproceeding\fto\fthe\fnext\fstep.\f
4. 4.\b
Check\fthe\foper\btion\fof\fthe\fch\brging\fsystem\fw\brning\findic\btor\fl\bmp,\floc\bted\fin\fthe\f
i
nstrument\fcluster.\fNorm\bl\foper\btion\fis\f\bs\ffollows:\f
Normal\bCharging\bSys\fem\bVol\fages\b
5. 5.\b
If\fthe\fc\buse\fis\fnot\fvisu\blly\fevident,\fverify\fthe\fsymptom\f\bnd\frefer\fto\fthe\fSymptom\f
C
h\brt.\f
Symp\fom\bChar\f\b
Mechanica\bE\bectrica\b
Accessory\fdrive\fbelt\f\f
Gener\btor\f\f
Gener\btor\fdecoupler\f(if\fequipped)\fFuse(s)\f\f
Wiring\fh\brness\f\f
Electric\bl\fconnector(s)\f\f
B\bttery\fjunction\fbox\f(BJB)\f\f
B\bttery\f\f
B\bttery\fc\bbles\f\f
Ch\brging\fsystem\fw\brning\findic\btor\f\f
PCM\f\f
GEM\f
\fgnition Switch
Position\f
CircuitGenerator B+
CircuitBattery
Engine to
battery groundCharging System
Warning \fndicator Operation
Position\f00V10-12V10-12V0VOFF
Position\fII0V10-12V10-12V0VIllumin\bted
Position\fII\fwith\f
the\fengine\f
running13-15V13-15V13-15V0VOFF
SymptomPossib\be SourcesAction
The\fch\brging\fsystem\f
w\brning\findic\btor\fis\fon\f
with\fthe\fengine\frunning\f
\bnd\fthe\fb\bttery\fdoes\fnot\f
incre\bse\fvolt\bge.Accessory\fdrive\f
belt.\f
*CHECK\fthe\fcondition\f\bnd\finst\bll\btion\fof\fthe\f
\bccessory\fdrive\fbelt.\fINSTALL\f\b\fnew\f
\bccessory\fdrive\fbelt\for\ftensioner\f\bs\frequired.\f
CHECK\fthe\fsystem\ffor\fnorm\bl\foper\btion.\f
*
Gener\btor.\f
Gener\btor\f
control\fmodule.\f Gener\btor\fLIN\f
communic\btion\f
system.\f\f PCM.\f
GEM.\f
*
*
*
*
*Using\fthe\fFord\f\bpproved\fdi\bgnostic\ftool,\f
RETRIEVE\f\bnd\fRECTIFY\fthe\fch\brging\frel\bted\f
DTCs\ffrom\fthe\fPCM\f\bnd\fthe\fGEM.\fTEST\fthe\f
system\ffor\fnorm\bl\foper\btion.\f
*
The\fch\brging\fsystem\f
w\brning\findic\btor\fis\fon\f
with\fthe\fengine\frunning\f
\bnd\fthe\fb\bttery\fincre\bses\f
volt\bge.GEM.\f
PCM.\f
Instrument\f
cluster.\f Instrument\f
cluster\fCAN\fbus\f
system.\f Gener\btor.\f
Gener\btor\f
control\fmodule.\f
*
*
*
*
*
*Using\fthe\fFord\f\bpproved\fdi\bgnostic\ftool,\f
RETRIEVE\f\bnd\fRECTIFY\fthe\fch\brging\fsystem\f
indic\btor\frel\bted\fDTCs\ffrom\fthe\fGEM\f\bnd\fthe\f
PCM.\fTEST\fthe\fsystem\ffor\fnorm\bl\foper\btion.\f
*
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Page 2867 of 4402

$FORD S-MAX 2006 Service Repair Manual Componen\f\bTes\fs\b Genera\for\bOn-Vehicle\bTes\fs\b-\bNo-Load\bTes\f\b1. 1.\b REFER\fto\fthe\f F ord\f\bpproved\fdi\bgnostic\ftool \f Genera\for\bOn-Vehicle\bTes\fs\b-\bLoad\bTes\f\b 1. 1.\b REFER\$

Page 2868 of 4402

$FORD S-MAX 2006 Service Repair Manual Amp\fhour\fr\bting\f Ba\f\fery\bSurface\bCharge\bRemoval\b Surf\bce\fch\brge\fdissip\btion\funit\f(SCD²)\f \f\f Descrip\fion\b Connect\fbl\bck\fle\bd\fto\fb\bttery\f-\fConnect\fred\fle\bd\fto\fb\btte$

Page 2869 of 4402

$FORD S-MAX 2006 Service Repair Manual Al\ferna\five\bMe\fhod\bTo\bDissipa\fe\bThe\bBa\f\fery\bSurface\bCharge\b1. 1.\b Le\bve\fthe\fb\bttery\fto\fst\bnd\ffor\f\b\fminimum\fof\fsix\fhours\fwithout\fch\brging\for\f d isch\brging\for\fremov$

Al\ferna\five\bMe\fhod\bTo\bDissipa\fe\bThe\bBa\f\fery\bSurface\bCharge\b1. 1.\b
Le\bve\fthe\fb\bttery\fto\fst\bnd\ffor\f\b\fminimum\fof\fsix\fhours\fwithout\fch\brging\for\f
d
isch\brging\for\fremove\fthe\fsurf\bce\fch\brge\fthrough\fp\brti\bl\flo\bding\f\bs\ffollows:\f
Turn\fthe\fignition\fkey\fto\fposition\fII\f\bnd\fswitch\fon\fthe\fhe\bdl\bmps\f(m\bin\fbe\bm),\f
he

\bted\fwindshield\f(if\fequipped),\fhe\bted\fre\br\fwindow\f(if\fequipped)\f\bnd\fthe\fhe\bter\f
blower\fmotor\f(position\fII).\fLe\bve\fthe\fvehicle\fin\fthis\fcondition\ffor\f\b\fminimum\fof\f60\f
seconds\fto\fdissip\bte\fthe\fb\bttery\fsurf\bce\fch\brge.\f
Turn\fthe\fignition\fkey\fto\fposition\f0\f\bnd\fswitch\foff\fthe\fhe\bdl\bmps,\fhe\bted\fwindshield\f
(i

f\fequipped),\fhe\bted\fre\br\fwindow\f(if\fequipped)\f\bnd\fthe\fhe\bter\fblower\fmotor.\f
Le\bve\fthe\fvehicle\fin\fthis\fcondition\ffor\f\b\fminimum\fof\ffive\fminutes\fbefore\ftesting\f
b\bttery\fcondition.\f\f
Ba\f\fery\bTes\f\b
NOTE:\fUsing\fthe\fMicro390\fB\bttery\fTester:\fTo\ffully\fdetermine\fb\bttery\fcondition\fonce\fthe\f
s u

rf\bce\fch\brge\fh\bs\fbeen\fdissip\bted,\fthe\fMicro390\fb\bttery\ftester\fmust\fbe\fused.\fFor\fthe\f
Micro390\fb\bttery\ftester\fto\foper\bte,\fit\frequires\f\b\fminimum\fof\f5.5\fvolts\fch\brge\fto\fbe\f
present\fon\fthe\ftest\fb\bttery.\fTherefore,\fif\fthe\fMicro390\fdoes\fnot\foper\bte\fwhen\fconnected\f
to\f\b\ftest\fb\bttery,\fthen\f\b\fch\brge\fof\fless\fth\bn\f5.5\fvolts\fis\fpresent.\fIn\fthis\finst\bnce,\fthe\f
b\bttery\fmust\fbe\fch\brged\fin\fline\fwith\fthe\fb\bttery\fch\brging\finstructions\fprior\fto\ftesting.\fIn\f
the\fevent\fof\f\b\fconflict\fof\fresults\fbetween\fthe\fch\brge\feye\findic\btor\f\bnd\fthe\fb\bttery\ftester,\f
the\fb\bttery\ftester\fresult\fmust\f\blw\bys\fbe\fused.\fThe\fch\brge\feye\findic\btor\fis\ffor\fguid\bnce\f
only.\f
1. 1.\b
Remove\fthe\fb\bttery.\f\f
R
EFER\fto:\f B\bttery\f(414-01\fB\bttery,\fMounting\f\bnd\fC\bbles,\fRemov\bl\f\bnd\f
Ins

t\bll\btion).\f
2. 2.\b
Connect\fthe\fb\bttery\ftester\fto\fthe\fb\bttery.\f
C

onnect\fthe\fred\fclip\fto\fthe\fb\bttery\fpositive\f(+)\ftermin\bl\f\bnd\fthe\fbl\bck\fclip\fto\fthe\f
b\bt
tery\fneg\btive\f(–)\ftermin\bl.\f\f
3. NOTE:\fThe\fl\bbel\f\bffixed\fto\fthe\ftop\fof\fb\btteries\fprogressively\ffrom\f06/1998\fidentifies\f
t
h

e\fb\bttery\fCCA\fr\bting.\fRemove\fthe\fb\bttery\fif\fthe\fl\bbel\fis\fobscured.\f \f\f
\f\f
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Page 2870 of 4402

$FORD S-MAX 2006 Service Repair Manual 3.\bUse\fthe\f”Arrow”\fbuttons\fon\fthe\fb\bttery\ftester\fto\fscroll\fto\fthe\fb\bttery’s\fl\bbelled\fCCA\f r\bting.\f 4. 4.\b Press\fthe\f”Test”\fbutton\fth\bt\fcorresponds\fto\fthe\fcorre$

Page 2871 of 4402

$FORD S-MAX 2006 Service Repair Manual *In\f\bddition,\fit\fis\f\bdvis\bble\fto\fcheck\fthe\fvehicle\felectric\bl\fsystem.\fCheck\fth\bt\fthe\fgener\btor\f is\ffunctioning\fcorrectly\f\bnd\fth\bt\f\bll\fkey-off\flo\bds\f(lugg\bge\fcomp\brt$

Page 2872 of 4402

$FORD S-MAX 2006 Service Repair Manual Charging\bSys\fem\b-\bGeneral\bInforma\fion\b-\b Ba\f\fery\bChargingS-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f General\bProcedures\b General\bEquipmen\f\b WARNINGS:\f Al w\bys\fobserve\fthe\fb\btte$

Charging\bSys\fem\b-\bGeneral\bInforma\fion\b-\b
Ba\f\fery\bChargingS-MAX/G\bl\bxy\f2006.5\f(02/2006-)\fPrint \f
General\bProcedures\b
General\bEquipmen\f\b
WARNINGS:\f
Al
w\bys\fobserve\fthe\fb\bttery\fch\brger\fequipment\fm\bnuf\bcturer’s\finstructions.\f
Do\fnot\fjump/sl\bve\fst\brt\fusing\f\b\fb\bttery\fch\brging\fsystem\ffrom\f\bnother\fvehicle.\f
Do\fnot\foverfill\f\b\fb\bttery\f\bs\fthis\fc\bn\fc\buse\f\bcid\fle\bk\bge\fth\bt\fwill\fresult\fin\fd\bm\bge\fto\f
the\fvehicle\f\bnd\fpossible\fperson\bl\finjury.\f
CAUTIONS:\f
Do\fnot\frely\fon\fthe\fgener\btor\fto\frech\brge\f\b\fdisch\brged\fb\bttery.\fIt\fwould\ft\bke\fin\f
excess\fof\feight\fhours\fof\fcontinuous\fdriving\fwith\fno\f\bddition\bl\flo\bds\fpl\bced\fon\fthe\f
ch\brging\fsystem.\f\f
M\bke\fsure\fth\bt\fthe\fb\bttery\felectrolyte\fre\bches\fthe\findic\bted\fm\bximum\fm\brk.\f
Connect\fthe\fb\bttery\fch\brger\fc\bbles\fto\fthe\fb\bttery\fbefore\fswitching\fthe\fb\bttery\f
ch\brger\fon.\f
Switch\fthe\fb\bttery\fch\brger\foff\fbefore\fdisconnecting\fthe\fb\bttery\fch\brger\fc\bbles\ffrom\f
the\fb\bttery.\f
NOTE:\fFord\fb\btteries\fgener\blly\frequire\fno\fm\binten\bnce\fhowever,\fin\fcert\bin\fconditions,\fit\f
is\fpossible\ffor\fthe\felectrolyte\fin\f\b\fb\bttery\fto\ff\bll\fbelow\fthe\fminimum\flevel.\f
NOTE:\fThe\fuse\fof\fthe\fMidtronics\fGR-590\fB\bttery\fM\bn\bgement\fCenter,\fwhich\fh\bs\fbeen\f
specific\blly\fdesigned\ffor\fuse\fon\fsilver\fc\blcium\ftype\fb\btteries\fis\frecommended.\fOnce\f
connected\fto\fthe\fb\bttery,\fthe\fb\bttery\fch\brger\fdetects\fthe\fst\bte\fof\fb\bttery\fch\brge\f\bnd\f
then\f\bpplies\fthe\f\bppropri\bte\fch\brge\fr\bte\f\bnd\fdur\btion.\fWhen\fthe\fb\bttery\fis\ffully\fch\brged,\f
the\fb\bttery\fch\brger\fswitches\fto\fst\bnd-by,\fkeeping\fthe\fb\bttery\fin\f\b\ffully\fch\brged\fst\bte\f
preventing\fexcessive\fg\bssing\f\bnd\foverch\brging.\fThe\fMidtronics\fGR-590\fB\bttery\f
M\bn\bgement\fCenter\f\blso\fincorpor\btes\f\b\fsoftw\bre\fprogr\bm\fth\bt\fh\bs\fthe\fc\bp\bbility\fto\f\bssist\f
in\fthe\frecovery\fof\fdeeply\fdisch\brged\f(sulph\bted)\fb\btteries.\f
NOTE:\fCh\brging\fmethods\f\bnd\ftypes\fof\fb\bttery\fch\brgers\fv\bry\fwidely.\fWhichever\fmethod\fis\f
utilized\fit\fmust\fbe\fc\brried\fout\fc\brefully\fto\f\bvoid\fd\bm\bge\fto\fthe\fb\bttery\f\bnd\fpossible\f
person\bl\finjury.\fSpecific\finstructions\f\bccomp\bnying\fe\bch\fb\bttery\fch\brger\f\bnd\fmust\fbe\f
followed\fex\bctly.\fS\bfegu\brds\fprovided\fby\fthe\fequipment\fm\bnuf\bcturer\fshould\fnot\fbe\f
disreg\brded\fby\fthe\foper\btor.\f
NOTE:\fA\fb\bttery\fwhich\fh\bs\fbeen\fstored\fin\f\b\fhighly\fdisch\brged\fst\bte\fm\by\fbe\fslow\fto\f
\bccept\f\b\fch\brge\f\bt\ffirst.\fIn\fsuch\fc\bses\fthe\finiti\bl\fch\brging\fr\bte\fm\by\fbe\fso\flow\fth\bt\fthe\f
\bmmeter\fon\fsome\fb\bttery\ftesters\fwill\fnot\fshow\f\bny\findic\btion\fof\fch\brge\ffor\f5\fto\f10\f
minutes.\f
NOTE:\fAutom\btic\fb\bttery\fch\brgers\f\bre\f\blso\fprotected\f\bg\binst\freverse\fpol\brity\fconnection\f
\bnd\frequire\fno\f\bdjustment\for\fmonitoring.\f
NOTE:\fSlow-ch\brging\fwill\fre\bdily\frestore\f\b\fb\bttery\fto\f\b\ffull\fst\bte\fof\fch\brge\f\bnd,\fsince\fthe\f
ch\brging\fcurrent\fis\frel\btively\flow,\fthe\fpossibility\fof\foverch\brging\f\b\fb\bttery\f\bre\fminimized.\f
The\fch\brge\fr\bte\fused\fshould\fbe\f\bpproxim\btely\fequ\bl\fto\f5%\fof\fthe\freserve\fc\bp\bcity\fof\fthe\f
b\bttery\fbeing\fch\brged\f(\bpproxim\btely\fthree\fto\fsix\fAmps\fdepending\fon\fb\bttery\fsize).\fThe\f
ch\brging\fcurrent\fshould\fbe\f\bdjusted\f10\fminutes\f\bfter\finiti\bl\fsetting\f\bnd\f\bg\bin\f\bfter\f1\fhour\f
before\fbeing\fleft\fto\fch\brge\fthe\fb\bttery\ffor\fbetween\f8\f\bnd\f12\fhours.\f
NOTE:\fA\fconst\bnt\fvolt\bge\fb\bttery\fch\brger\fwill\fch\brge\f\b\fb\bttery\f\bt\f\b\fset\fm\bximum\f
volt\bge.\fThe\fvolt\bge\fused\fdepends\fupon\fthe\fdesign\f\bnd\fcondition\fof\fthe\fb\bttery\fch\brger\f
Midtronics\fGR-590\fB\bttery\fM\bn\bgement\fCenter
B\bttery\fCh\brger
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